version: 1.1
date: 2023-10-17

Technical Requirements forExtension of Automatic Warehouse

REVISION HISTORY
Rev. no.
1.0
1.1

Date
2023-09-05
2023-10-17

2023-10-17 v1.1

Author
Piotr Polewiak
Piotr Polewiak

Description
Creation of the document.
Minor updates.

Technical Requirements

2 / 15TABLE OF CONTENTS
Revision history ....................................................................................................................................... 2
Table of contents ..................................................................................................................................... 3
1

Definitions ....................................................................................................................................... 52

Installation site ................................................................................................................................ 6

3

Process description.......................................................................................................................... 7

4

Required technical parameters and machine requirements .......................................................... 7
4.1

Dimensions of current warehouse area designed for installation .......................................... 7

4.2

Required performance of offered technology ........................................................................ 8

4.3

Locations: ................................................................................................................................ 8

4.3.1

Dimension........................................................................................................................ 8

4.3.2

Quantity ........................................................................................................................... 8

4.4

Tote.......................................................................................................................................... 9

4.4.1

Dimension........................................................................................................................ 94.4.2

Mass................................................................................................................................. 9

4.4.3

Service outside AW.......................................................................................................... 9

4.4.4

Currently used ................................................................................................................. 9

4.5

Efficiency and failures............................................................................................................ 10

4.5.1

Emergency Process ........................................................................................................ 10

4.5.2

Redundancy ................................................................................................................... 10

4.5.3

Overall Equipment Efficiency (OEE)............................................................................... 10

4.5.4

Maintenance.................................................................................................................. 10

4.6

Basic and machine to machine (M2M) communication ....................................................... 11

4.6.1

Communication interface with: ..................................................................................... 11

4.6.2

Contractor’s VPN access to the machine for service purposes: .................................... 11

4.6.3

Automatic transmission of AW diagnostic information to the TME system: ................ 11

4.6.4

Date and time synchronization ..................................................................................... 11

4.7

Software and hardware ......................................................................................................... 11

4.7.1

Enterprise Resources Planning (ERP) ............................................................................ 11

4.7.2

Warehouse management system (WMS) ..................................................................... 11

4.7.3

Warehouse control system (WCS) / Material flow control (MFC) ................................ 12

4.7.4

Integration ..................................................................................................................... 12

4.7.5

IT Infrastructure............................................................................................................. 12

4.8

Firefighting guidelines ........................................................................................................... 12

4.9

Directives and standards ....................................................................................................... 132023-10-17 v1.1

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4.10

Technology currently being implemented ............................................................................ 13

5

Return on Investment (ROI) .......................................................................................................... 14

6

Schedule ........................................................................................................................................ 15

7

Remarks ......................................................................................................................................... 15

8

Appendices .................................................................................................................................... 152023-10-17 v1.1

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1 DEFINITIONS
The following list contains definitions of selected terms and abbreviations used in this document.
Definitions are capitalised.
1. The Ordering Party – Transfer Multisort Elektronik Sp. z o.o., ul. Ustronna 41, 93-350 Łódź,Poland (hereinafter referred to as “TME”)
2. The Bider – supplier of the machine described in this document.
3. Rzgów Logistics Centre (hereinafter referred to as CLR) – TME's new logistics centre, address:
ul. Nasienna 4, Gospodarz, 95-030 Rzgów, Poland
4. Automatic Warehouse (AW) – an automated warehouse built in the high storage zone based on
selected technologies in the CLR.
5. Goods – unprocessed material good intended for sale.
6. High storage area – part of CLR where the Automatic Warehouse is located, as well as conveyors
and machines supporting the Automatic Warehouse.
7. Location – specifying a place in the form of a sequence of letters and numbers (bookshelf,column, shelf, place on a shelf). The Location is necessary to find the Goods automatically or
manually in order to complete the customer's order.
8. Picking Area Automatic Warehouse (PAAW) – The work area and the entire technologicalinfrastructure supporting the processes around AW.
9. Product – a specific, identifiable and issued Good intended for a specific TME customer. The
Goods together with the collective packaging and the release label constitute the Product.
10. Tote – a plastic container enabling the transport of Goods or Products on the conveyors.

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2 INSTALLATION SITE
1. The Extension of Automatic Warehouse installation will be in the CLR in the part of High storagearea.
2. The part of High storage area is marked with a green rectangle in the figure below (Figure 1).

Figure 1

3. A simplified 2D view of the part of High storage area (Figure 2).

Figure 2

4. A simplified 3D view of the area planned for use in the Extension of Automatic Warehouse project(Figure 3).

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Figure 3

5. The area marked with a red floor is planned for use in the Extension of Automatic Warehouseproject.
6. The interface connecting the AW and the PAAW may be located outside the High storage area.
7. Detailed layout is in the appendix (chapter: 8 Appendices point 1 Layout (DWG format file from
AutoCAD)).

3 PROCESS DESCRIPTION
1. AW will handle the Totes for the process:a) of issuing and receiving (Totes with Goods or without Goods),b) of consolidation (Totes with Products) andc) others (Totes with Goods or without Goods).
2. During the consolidation process, Totes with Products from the same order are temporarily stored
in AW.
3. Totes delivered to AW (inbound) and Totes received from AW (outbound) will be transported onconveyors that are part of PAAW.

4 REQUIRED TECHNICAL PARAMETERS AND MACHINE REQUIREMENTS
4.1 DIMENSIONS OF CURRENT WAREHOUSE AREA DESIGNED FOR INSTALLATION
1. Available space: 1500 m2.
2. Dimensions:a) length: ~65 m,b) width: ~23 m,

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7 / 15c) height: 12.3 m.
3. Detailed dimensions are available in the appendices (chapter: 8 Appendices).
4. The interface with AW can be located outside the High storage area.

4.2 REQUIRED PERFORMANCE OF OFFERED TECHNOLOGYAW total performance after Extension of Automatic Warehouse (technology currently being
implemented described in chapter 4.10 Technology currently being implemented and technology ofExtension of Automatic Warehouse) is the number of Totes in 1 hour for the issuing and receiving
process plus the number of Totes in 1 hour for the consolidation process.
1. Total:a) number of inbound Totes: min 2400 pcs/h,b) number of outbound Totes: min 2400 pcs/h.
2. Issuing and receiving:a) number of inbound Totes: min 2000 pcs/h,b) number of outbound Totes: min 2000 pcs/h.
3. Consolidation and others:a) number of inbound Totes: min 400 pcs/h,b) number of outbound Totes: min 400 pcs/h.
Required performance of the Extension of Automatic Warehouse is at least 65% of AW total
performance outlined above.
Planned work 6 days a week (Monday-Saturday), 24 hours a day. Possibility of stopping for 1 hour in aweek due to scheduled service (e.g. Friday from 22:00 to 23:00).
Frequency (many in one second and single every many seconds) and number (multiple requests
simultaneously or single requests one at a time) of Tote requests sent by TME will vary and cannot
reduce the minimum performance requirements (chapter 4.2 Required performance of offeredtechnology).

4.3 LOCATIONS:
4.3.1 Dimension
1. The dimensions of the Location depend on the dimensions of the footprint (length x width) of theTote.
2. The Locations of the Totes for the process of issuing and receiving will be:a) a standard height.
3. The Locations for the Totes for the consolidation process will be:a) a standard height orb) an increased height.
4. The standard height is determined by the height of the Tote.
5. The increased height is determined by the height of the Tote with the maximum protruding
Products.
4.3.2 Quantity
1. The minimum total number of Locations: 74000 pieces.
2. The minimum number of Locations with an increased height (defined below as “height withprotruding Products”): 2000 pieces or the entire level / row / column of storage racks.

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3. Optional increase in the number of Locations in the future (e.g. additional racks or additional levelsof already existing racks), if the technology used makes it possible.

4.4 TOTE
4.4.1 Dimension
1. External dimensions (length x width x height): 600 x 400 x 170 mm.
2. Height with protruding Products: max 325 mm,a) Products may protrude max 155 mm.
3. Internal volume: 34 litres.
4.4.2 Mass
1. Mass of Goods or Products in a Tote and mass of a Tote: max 20 kg.
2. The centre of gravity of the Goods or Products in the Tote may be unevenly distributed.
4.4.3 Service outside AW
1. The Totes handled by AW will also be used in other processes both in the CLR and outside the CLR.
4.4.4 Currently used
Requirements for Totes currently used by TME:
1. Sample photo:

Figure 4

2.
3.
4.
5.
6.
7.

Material: Polypropylene (PP);
Colour: preferably light grey;
Solid sidewall;
Solid base;
Empty Tote mass: ~1,9-2,1 kg;
The centre of gravity of the Tote with Goods or Products in the vertical plane is not higher than
1/2 the height of the Goods or Products or the Tote (whichever is higher);
8. The centre of gravity of the Totes with Goods or Products in the horizontal plane is not more than
1/4 of the Tote length;
9. The deformation of the bottom of the Tote is not greater than 6 mm (1% of the length);
10. There is a unique barcode identifying the Tote on both long side walls;

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11. Some of the Totes have evenly spread bores (Figure 4) in accordance with VdS CEA 4001 Anex
K.7.1.

4.5 EFFICIENCY AND FAILURES
4.5.1 Emergency Process
1. Possibility of manual release of the Goods or Products directly from the Location in the case of
failure of the devices for the automatic collection of Totes.
4.5.2 Redundancy
1. Redundancy for parts of devices operating in AW is being considered, if the technological solution
proposed by the Contractor requires it.
4.5.3 Overall Equipment Efficiency (OEE)
1. The Contractor must provide information enabling the calculation of the OEE for the offeredmachine.
2. Expected OEE metric will not be taken into account in the quotation process.
3. Information enabling the calculation of the OEE and procedure for calculation of the OEE isavailable in ISO 22400-2 standard.
4. Expected OEE metric calculated according to ISO 22400-2 standard is in chapter 8 Appendices point
3 Overall Equipment Efficiency (OEE) calculation.
5. Expected OEE is > 90% with metrics:a) Availability is > 98%,b) Effectiveness is > 92%,c) Quality is > 99,9%.
4.5.4 Maintenance
1. Availability of manual motors control (on/off, up to position in mm defined by operator, up to
default positions configured).
2. The ability to check the history of the tote from the moment it enters inbound interface, throughstorage, to its possible exit from outbound interface.
3. Preventing the tote from being pushed too deep on the Location.
4. Ability to export a text file containing an information about:a) exceptions of drives andb) communication between Contractor’s software and TME’s WMS software.
5. Report from checking all Locations that they are correctly positioned delivered for TME acceptance
before SAT.
6. Automatic management of the battery charge of the robots (if robots are required), so that thesimultaneous discharge of the batteries of many robots does not reduce performance.
7. The functionality of safely putting the tote back on the rack without using the manual control mode
when there was a problem with retrieving the tote from the rack (e.g after pressing an emergency
top button).
8. The procedure for safely bringing all the drives without electric power supply to the home position
must be described in the service manual.
9. Entering to the operation area will reduced speed of devices to safe speed instead of stopping
devices.
10. Preventing the robot (if robots are required) from moving outside the designed traffic paths (e.g.
a problem with reading DM Floor codes) in automatic mode. Hitting the other devices, racks, safety
fence, etc. by robot is unacceptable.

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4.6 BASIC AND MACHINE TO MACHINE (M2M) COMMUNICATION
4.6.1 Communication interface with:
1. TME's industrial automation systems (e.g. PLC) using:a) PROFINET network;
2. TME's safety control systems (e.g. safety PLC) using:a) PROFIsafe network (preferred);b) relay inputs / outputs 24 VDC;
3. TME's IT systems (chapter 4.7 Software and hardware) using Ethernet.
4.6.2 Contractor’s VPN access to the machine for service purposes:
1. According to TME procedure and signed NDA,
2. TME's ICT network security policy requires remote VPN access to machines to be performed via
VPN managed by TME,
3. TME uses Fortinet solution with the FortiClient application.
4.6.3 Automatic transmission of AW diagnostic information to the TME system:
1. Interface using:a) PROFINET network (preferred),b) Ethernet TCP/IP (acceptable),c) relay inputs / outputs 24 VDC (not preferred);
2. Diagnostic information:a) live bit / heartbeat (if network communication),b) machine status,c) alarm code,d) at the time of an alarm:• machine step,• pending requests from MFC,
• device coordinates (stacker cranes, trolleys, mobile robots, lifts).
4.6.4 Date and time synchronization
1. Using Network Time Protocol (NTP).
2. Actual time on HMI clock, alarms time stamps, logs.

4.7 SOFTWARE AND HARDWARE
4.7.1 Enterprise Resources Planning (ERP)
1. Vendor:a) TME uses ERP software provided by the external supplier (SAP SE).
4.7.2 Warehouse management system (WMS)
1. Vendor:a) TME uses WMS software provided by the TME software departments and by external supplier(SAP SE),b) WMS software for AW may be provided by the Contractor and integrated with TME's softwarein cooperation with TME's software development departments.
2. Requested features:a) The process of automatic relocation of Totes within the AW is not envisaged when its rotation
class changes. On-demand relocation is foreseen,b) Possibility to manage the AW with racks of any depth (when such technology is finallyselected),

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c) The storage Location of the Tote must be known at all times,d) The software should enable checking the availability status of AW internal devices by an API
interface.
4.7.3 Warehouse control system (WCS) / Material flow control (MFC)
1. Vendor:a) TME uses software provided by the TME software departments and by external supplier.
4.7.4 Integration
1. The software provided by the Contractor can be integrated with ERP, WMS or WCS/MFC at adifferent level of detail for the information exchange.
2. Determining software communication details (i.e. overview of interface management, format ofmessages, storage and retrieval messages).
3. Determining IT infrastructure details (i.e. servers hardware, licensing, virtualization, data base,backups, network).
4. Determining the time from the moment the tote request is sent by TME until the tote leaves AW.
5. Software managing mobile robots shell communicate with TME's IT system using JSON over HTTPs
protocol.
4.7.5 IT Infrastructure
1. Business network:a) Building a business network directly by Contractor or by a subcontractor on the part ofContractor in consultation with TME.
b) Safety network, that is provided by Contractor in actual offer, will not interfere with thebusiness network.
2. The Contractor:a) Will provide maintenance of physical infrastructure (network) and application infrastructure(software, operating system) during the entire maintenance period (compatible with thesupport period for the whole system).
b) Will provide WLAN infrastructure based on Fortinet hardware compatible with Forti WLC.
c) Will provide all servers as virtual machines:• delivered in the form of Open Virtualization Format (OVF) and,• compatible with VMware 7.0 and,• in a configuration in accordance with the specification provided at the project design
stage.
d) Will perform all required works related to the maintenance and ensuring IT security (upgrades,
patching, maintenance, configuration changes) during the entire guarantee period.
e) Will provide complete as-built documentation (hardware, network, application, both physicaland logical parts).
f) Will provide reports of cyclical WLAN inspections performed.
g) Conduct training during implementation on diagnosing failures of individual components ofthe delivered technology.

4.8 FIREFIGHTING GUIDELINES
1. The AW construction (i.e. racks) and technology (i.e. machines) together with the accessories (i.e.
Totes) must meet the VdS CEA 4001 – Guidelines for Sprinkler Systems, version 2021-01 (7).
2. The AW technology must be adapted to Totes without bores in the bottom in accordance with VdS
CEA 4001 Annex K.7.1.
3. TME expects the Contractor's experience in the use of fire suppression system in automatic highstorage warehouses (no bores, vertical and horizontal distance between sprinklers, horizontal
sheet metal barriers).

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4. The current construction of the CLR building makes it impossible to apply the inertization process.
5. The fire alarm system (FAS) sends alarm signal to the Contractor’s software by API. The FAS alarm
causes the fixed devices to stop and mobile devices to interrupt their tasks, move to the place
configured by TME and stop.

4.9 DIRECTIVES AND STANDARDS
1. Required compliance with the mandatory European Union directives, in particular:a) Directive 2006/42/EC - MD (Machinery Directive),b) Directive 2014/35/EU - LVD (Low Voltage Directive),c) Directive 2014/30/EU - EMC (Electromagnetic Compatibility Directive),d) Directive 2014/53/EU - RED (Radio Equipment Directive),
2. Machinery manufacturer that apply procedure for assessment of conformity described in directive
2006/42/EC Article 12 paragraph 2 or Article 13 must use harmonised standards:a) Some relevant harmonised standards are listed in chapter 8 Appendices point 4 Harmonised
standards,b) Harmonised standards must be taken into account if they apply to the offered machine,c) The harmonised standard in the most recent version must be used,d) An external auditor will check compliance with the directives and standards.
3. Documents listed below must be provided to the Ordering Party as soon as possible after the orderis placed:a) Manuals (i.e. operation, maintenance),b) Control circuit diagrams (i.e. electric, pneumatic),c) Risk assessment in accordance with EN ISO 12100,d) Performance level in accordance with EN ISO 13849-1.
4. Consistent terminology/names and symbols in all documents (e.g. electrical diagrams, manuals,
technical drawings, layouts, control panels) supplied by the Contractor are required.

4.10 TECHNOLOGY CURRENTLY BEING IMPLEMENTED
Automatic warehouse operated by mobile robots (driverless industrial trucks).
Details:
1. Height of racks: 12,2 m.
2. Storage height: up to 10,0 m.
3. Width of aisles between racks: 116 cm.
4. Number of localizations on rack: 19 943 pcs.
5. Each localization on rack can handle either two Locations (two stacked Totes) or one Location withincreased height (Totes with protruding Products)
6. Number of robots: 29 pcs.
7. Functionalities of mobile robots:a) determining the optimal route,b) transporting many totes simultaneously,c) loading inbound totes and unloading outbound totes by dedicated machines that interface
with PAAW conveyors,d) compliance with the EN ISO 3691-4:2020 standard,e) enabling safe operation of the robot in confined zone and in zones where presence of people
is expected,f) equipped with pressure-sensitive and electro sensitive protective equipment.
8. WLAN safety communication.

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9. Handling single tote and two stacked totes.
10. Communication with TME's IT system using JSON over HTTPs protocol.
11. Racks layouta) General information:

Figure 5b) Detailed information are available after signing NDA.
Compatibility with technology currently being implemented:a) Devices that are offered must operate in rack Locations of technology currently being
implemented.
b) Devices of technology currently being implemented must operate in rack Locations that are
offered.

5 RETURN ON INVESTMENT (ROI)
1. The supplier should provide information enabling the calculation of the ROI for the offeredmachine:a) CAPEX:• storage system / hardware,• software system,• other equipment,

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14 / 15• implementation & commissioning,• transportation;b) OPEX in 10 years:• service costs,• maintenance costs,• software licenses costs,• economic useful life (EUL) e.g. battery replacement costs,• amount of electricity consumption [kWh / hour],• amount of pressured air consumption [litters / hour];c) Other information:• exact used space that meets requirements listed in chapter 4.1 Dimensions [m2],• exact performance that meets requirements listed in chapter 4.2 Required performanceof offered technology [Totes pcs / hour],• exact number of totes Locations that meets the requirements listed in chapter 4.3.2
Quantity [Locations pcs].
2. That information will not be taken into account in the quotation process.

6 SCHEDULE
1. After the Ordering Party accepts the Contractor's offer, the Contractor must prepare a work
schedule comprising at least the points listed below:a) Start of the work,b) Approval of the technical specifications, functional specifications and the 3D model provided
by the Contractor,c) Factory Acceptance Tests (FAT),d) Delivery,e) Installation,f) Commissioning,g) Handover of acceptance documentation,h) Site Acceptance Tests (SAT),i) Signing of the handover and acceptance report.

7 REMARKS
1. If the Contractor has any doubts as to the content of this document, such doubts should be
immediately reported to the Ordering Party.
2. The contractor must familiarize himself with the assembly site and request from TME all necessary
data and information that may affect the performance of the subject of the contract.

8 APPENDICESThe following documents can be delivered to the Contractor in an electronic version:
1. Layout (DWG format file from AutoCAD)
2. 3D model (FSM format file from FlexSim)
3. Overall Equipment Efficiency (OEE) calculation
4. Harmonised standards

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